Sock with gripping dots and a method of making same

ABSTRACT

A sock construction that substantially prevents wrinkling and bunching of the sock within the shoe. The sock construction includes a multiplicity of strategically located gripping dots disposed on the interior surface of the sock which effectively resist slippage of the sock relative to the user&#39;s foot. The gripping dots are strategically positioned so as not to restrict blood flow to the foot and so as not to inhibit normal blood circulation within the foot.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to socks and methods for makingsame. More particularly, the invention concerns an improved grippingsock having a friction-gripping surface consisting of a multiplicity ofclosely positioned gripping dots provided on the interior surface of thefoot portion of the sock.

2. Discussion of the Prior Art

A variety of different types of socks have been produced in the pastfrom various materials, including natural and synthetic yarns. Styles ofprior art socks include dress socks, socks for casual wear, athleticsocks and special-purpose socks for special activities.

As a general rule, socks are made by knitting using circular knittingmachines. Such machines typically knit a tubular fabric structure usinga multiplicity of closely controlled latch needles and sinkers on alength of yarn. One form of prior art circular knitting machine iscommercially available from the Lonati Company, S.P.A. of Brescia,Italy. In this machine the knitting action and stitch density iscontrolled by a program of instructions installed in a microprocessor.

Prior art socks are generally knitted with a rim surrounding an openingat the leg portion and an opening at the toe portion. The toe opening ofa machine knit sock is typically closed in a separate operationperformed on one of several different types of commercially availableautomatic sewing machines.

The interaction between the sock and the wearer's foot can have aprofound impact on the comfort and well being of the user. For example,a wrinkle or a bunching of the stock within the shoe will, overtime,likely cause friction and skin shear which, in turn, can cause blisters,ulcers or other debilitating conditions. This result can be particularlysevere with persons having poor circulation, such as persons sufferingwith diabetes and certain other types of physical disabilities.

Experience has shown that unless both the sock and the shoe fit nearlyperfectly, wrinkling and bunching of the sock within the shoe isgenerally unavoidable. It is this problem that the present inventionseeks to overcome by providing a novel sock and the method of makingsame that will substantially prevent unwanted wrinkling and bunching ofthe wearer's sock within the shoe even during periods of prolongedwalking and exercise.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a novel sockconstruction that substantially prevents wrinkling and bunching of thesock within the shoe. More particularly, it is an object of theinvention to provide a sock construction which includes a multiplicityof strategically located gripping dots disposed on the interior surfaceof the sock which effectively resist slippage of the sock relative tothe user's foot.

A further important object of the present invention is to provide a sockof the aforementioned character that effectively prevents slippage ofthe sock relative to the user's foot without restricting blood flow tothe foot and without inhibiting normal blood circulation within thefoot.

Another object of the invention is to provide a novel method forefficiently and cost effectively producing socks of the characterdescribed in the preceding paragraphs.

Another object of the invention is to provide a stretchable sock of theaforementioned character and the method of making the sock wherein thesock is provided with a multiplicity of gripping dots spaced such thatthe stretch quality of the sock is not restricted by the excessivecoverage of the knit fabric by the grip-dots.

In accordance with these and other objects, the present inventionconcerns a sock comprising an open top, seamless, fabric receptacle thatextends downwardly to a closed toe end. The receptacle includes atapered toe section that projects from the toe end and is configured toreceive the toes of the wearer, a tubular generally straight-leg sectionthat is adjacent the leg end and is dimensioned to receive at least aportion of the leg of the wearer, and a tubular, generally straight-footsection extending between the leg section and toe section. The toe, footand leg sections of the receptacle can be knitted of a common,high-stretch yarn and are preferably configured to cause the yarn tostretch when the sock is donned. In one embodiment of the invention, theyarn comprises multiple corespun strands, each of which includes anelastomeric core and an outer sheath of substantially non-elasticfibers. This construction provides a highly stretchable, form-fittingsock that is free of seams.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a generally perspective view of a sock of the character usedin connection with the method of the present invention showing theexterior surface thereof.

FIG. 2 is a generally perspective view of the sock shown in FIG. 1 butturned inside out to show the interior surface thereof.

FIG. 3 is a generally perspective view of one form of the sock supportmandrel used in connection with the performance of one embodiment of themethod of the invention.

FIG. 4 is an enlarged fragmentary view of the area designated in FIG. 3as 4-4.

FIG. 5 is a generally perspective view showing the inside out sock ofFIG. 2 positioned over the support mandrel shown in FIG. 3 of thedrawings.

FIG. 6 is an enlarged fragmentary view of the area designated in FIG. 5as 6-6.

FIG. 7 is a generally perspective, diagrammatic view illustrating thefirst step in one form of the method of the invention namely using anapertured stencil for depositing polymer grip-dots on the interiorsurface of the sock.

FIG. 8 is a generally perspective diagrammatic view illustrating thesecond step in one form of the method of the invention, namely usingcuring means superimposed over the sock for curing the polymer grip-dotsemplaced on the interior surface of the starting sock of the invention.

FIG. 9 is a generally perspective view showing the sock illustrated inFIG. 2 as it appears after being turned inside out and after thegrip-dots have been deposited on the interior surface of the sock andcured with the curing means of the invention.

FIG. 10 is a generally perspective, diagrammatic view illustrating thepositioning of the starting sock shown in FIG. 2 of the drawings inposition to be emplaced over the support mandrel of an alternate form ofapparatus of the invention.

FIG. 11 is a generally perspective, diagrammatic view illustrating thestarting sock positioned over the support mandrel and showing analternate form of the stencil member positioned over the surface of thesock upon which grip-dots are to be deposited.

FIG. 12 is a generally perspective, diagrammatic view illustrating analternate form of curing means of the invention positioned over thepolymer emulsion grip-dots that have been emplaced on the inside surfaceof the starting sock.

FIG. 13 is a generally perspective view of the inside surface of thesock as it appears following the step of curing the polymer emulsion ofthe grip-dots.

FIG. 14 is a view of the finished sock of this latest form of theinvention, partly broken away to illustrate the positioning of thegrip-dots on the inside surface of the lower portion of the sock.

FIG. 15 is a generally diagrammatic, side view illustrating the startingsock shown in FIG. 2 positioned over a support mandrel of still adifferent configuration.

FIG. 16 is an enlarged cross-sectional view taken along line 16-16 ofFIG. 15.

FIG. 17 is a generally perspective, diagrammatic view illustrating thepositioning of an alternate form of template of the apparatus of theinvention positioned over the surface of the starting sock upon whichthe grip-dots are to be deposited.

FIG. 18 is a generally perspective diagrammatic view showing the curingmeans of this latest form of the apparatus of the invention positionedover the grip-dots that have been deposited on the first side of thestarting sock.

FIG. 19 is a generally perspective, diagrammatic view, similar to FIG.17, but showing the sock and mandrel sub-assembly turned over so thatgrip-dots can be deposited on the opposite side of the starting sock.

FIG. 20 is a view similar to FIG. 18, but showing the curing means ofthe apparatus of the invention positioned over the second side of thestarting sock upon which the polymer emulsion grip-dots have beendeposited.

DESCRIPTION OF THE INVENTION

Referring to the drawings and particularly to FIGS. 1 through 9, oneform of the method and apparatus of the invention is there illustrated.FIG. 1 depicts a sock 24 of the character used in connection with themethod of the present invention showing the exterior surface 24 athereof. FIG. 2 is a generally perspective view of the sock shown inFIG. 1, but turned inside out to show the interior surface 24 b thereof.

Sock 24 comprises an open top, seamless, fabric enclosure that extendsdownwardly to a closed toe end. The enclosure includes a tapered toesection 24 c that projects from the toe end and is configured to receivethe toes of the wearer, a tubular generally straight-leg section 24 dthat is adjacent the leg end and is dimensioned to receive at least aportion of the leg of the wearer and a tubular, generally straight-footsection 24 e extending between the leg section and toe section. The footsection includes a lower portion 24 f having an inner surface thatengages the bottom portions of the user's foot. The toe, foot and legsections of the enclosure are preferably knitted of a yam that willpermit stretching when the sock is donned.

FIG. 3 is a generally perspective view of one form of a sock supportmandrel 26 used in connection with the performance of the first form ofthe method of the invention. As indicated in FIG. 3, mandrel 26, whichcomprises a portion of the apparatus of one form of the invention,includes an elongated, generally planar aluminum support member 28having first and second ends 28 a and 28 b. Formed intermediate ends 28a and 28 b is a sock supporting planar portion 29 and a strategicallyshaped aperture 30 which defines a generally “V”-shaped sock captureelement 32 the purpose of which will presently be described. Mandrel end28 a is preferably tapered, while mandrel end 28 b comprises a segment34 of reduced width.

In the performance of one form of the method of the invention the turnedinside out starting sock shown in FIG. 2 is stretched over the mandrelin the manner shown in FIGS. 5 and 6 with the capture element 32 ingripping engagement with a capture area on the leg receiving portion ofthe sock. With this construction, the turned inside out starting sock issecurely held in position over the mandrel with the lower, or soleportion 24 f of the foot receiving part of the starting sock beingflattened and urged against the generally planar support portion 29 ofthe mandrel. When the starting sock is properly positioned over themandrel in the manner shown in FIG. 5 of the drawings to form a firstassemblage, the foot engaging portion of the first, or interior surface24 b is exposed and is maintained in a substantially planarconfiguration.

Turning next to FIG. 7 of the drawings, a generally perspective,diagrammatic view illustrating the emulsion deposition step of one formof the method of the invention is there shown. This step involves theuse of a specially designed, apertured stencil 38, which also forms apart of the apparatus of the invention. Apertured stencil 38, whichincludes a central portion having a multiplicity of spaced-apart dotforming apertures 38 a, functions to permit the uniform deposition of aselected grip-dot forming emulsion on the foot engaging portion of theinterior surface 24 b of the sock. The grip-dot forming emulsion can beselected from a number of well known prior art curable emulsions,including polymer emulsions, polyvinyl chloride emulsions and the like.

In the performance of the emulsion deposition step, the aperturedstencil 38 is positioned above the first assemblage 40 in the mannershown in FIG. 7. Then, using a squeegee or the like (not shown), theselected emulsion, such as a liquid vinyl material, is forced throughthe apertures 38 a in a manner such that a multiplicity of spaced-apart,uncured grip-dots 42 are controllably deposited on the foot engagingportion of the interior surface 24 b of the sock to form an uncuredfirst precursor (see FIG. 8). This done, the uncured grip-dots 42 arethen controllably cured into yieldably deformable cured grip-dots 42 a.

This curing step is accomplished using a curing means for curing theemulsion, such as the radiation emitting device 44 shown in FIG. 8 ofthe drawings. Device 44 functions to controllably cure the uncuredgrip-dots so as to form a first cured precursor. The radiation means cancomprise either an irradiation device, such as the device 44 thatproduces infrared heat, or depending on the formulation of the emulsionused to form the uncured grip-dots it can comprise an irradiation devicethat produces ultraviolet light. When certain emulsions are used, theradiation means can also comprise a conventional heating means forcontrollably heating the uncured grip-dots. Radiation means appropriatefor use in carrying out the method of the present invention are wellknown to those skilled in the art and are readily commerciallyavailable. It is to be understood that in practice the uncured firstprecursor could be positioned on a conveyor belt and passed beneath theradiation means in a manner to cure the uncured grip-dots 42.

Following the curing step, the first cured precursor thus formed isremoved from the mandrel by disengaging the sock from the generally“V”-shaped gripping element and sliding the cured precursor over the endof the mandrel 26. As depicted in FIG. 9 of the drawings, the firstprecursor uniquely includes a multiplicity of gripping dots 42 a whichare strategically located on the lower foot portion of the sock which isnormally in engagement with the foot of the user when the sock is turnedinside out and donned by the user. As previously mentioned, after thesock is donned by the user, the strategically located gripping dots 42 afunction to effectively prevent slippage of the sock relative to theuser's foot thereby avoiding blisters and uncomfortable bunching of thesock within the user's shoe.

Turning now to FIG. 10, an alternate form of three-dimensional socksupport mandrel 50 is there shown for use in connection with theperformance of a second, alternate form of the method of the invention.As indicated in FIG. 10, mandrel 50, which comprises a part of theapparatus of one form of the invention, includes a generally cylindricalportion 52 for receiving the tubular, generally straight-leg section 24d of the starting sock and a base portion 54 connected to the generallycylindrical portion. Base portion 54 includes a sock supporting,generally planar portion 56 for supporting lower portion 24 f of thestarting sock.

In the performance of the alternate form of the method of the invention,the turned inside out starting sock shown in FIG. 2 is stretched overthe mandrel 50 in the manner shown in FIGS. 11 and 12. With thisconstruction, the turned inside out starting sock is securely held inposition over the mandrel with the lower, or sole portion 24 f of thefoot receiving part of the starting sock being flattened and urgedagainst the generally planar support portion 56 of the mandrel. When thestarting sock is properly positioned over the mandrel in the mannershown in FIG. 11 of the drawings to form a first assemblage, the footengaging portion of the first or interior surface 24 b of the sock isexposed and is maintained in a substantially planar configuration.

Turning to FIG. 11 of the drawings, a generally perspective,diagrammatic view illustrating the emulsion deposition step of thisalternate form of the method of the invention is there shown. This stepinvolves the use of a specially designed, apertured stencil 58, whichalso forms a part of the apparatus of the invention. Apertured stencil58, which includes a central portion having a multiplicity ofspaced-apart dot forming apertures 58 a, functions to permit the uniformdeposition of a selected grip-dot forming emulsion on the foot engagingportion of the interior surface 24 b of the sock. As before, thegrip-dot forming emulsion can be selected from a number of well knownprior art curable emulsions, including polymer emulsions, polyvinylchloride emulsions and the like.

In the performance of the emulsion deposition step of this alternateform of the invention, the apertured stencil 58 is positioned above thefirst assemblage 60 in the manner shown in FIG. 11. Then, using asqueegee or the like (not shown), the selected emulsion, such as apolymer emulsion, is forced through the apertures 58 a in a manner suchthat a multiplicity of spaced-apart, uncured grip-dots 62 arecontrollably deposited on the foot engaging portion of the interiorsurface 24 b of the sock to form an uncured first precursor (see FIG.12). This done, the uncured grip-dots 62 are then controllably curedinto yieldably deformable, rubber-like cured grip-dots 62 a. This curingstep is accomplished in the manner previously described using a curingmeans for curing the emulsion, such as the radiation emitting device 44shown in FIG. 12 of the drawings, to cure the uncured grip-dots in amanner to form a first cured precursor 63.

Following the curing step, the first cured precursor thus formed isremoved from the mandrel 50. As depicted in FIG. 13 of the drawings, thefirst precursor 63 uniquely includes a multiplicity of gripping dots 62a which are strategically located on the lower foot portion of the sockwhich is normally in engagement with the foot of the user when the sockis turned inside out in the manner shown in FIG. 14 and subsequentlydonned by the user. After the sock is donned by the user, thestrategically located gripping dots 62 a function to effectively preventslippage of the sock relative to the user's foot.

Referring now to FIGS. 15 and 16, still another form of sock supportmandrel 66 is there shown for use in connection with the performance ofa third, alternate form of the method of the invention. As indicated inthe drawings, mandrel 66, which also comprises a part of the apparatusof the invention, comprises a substantially rigid, aluminum mandrel 66which has the general shape of a human foot, but is somewhat larger thanthe size of a normal human foot. Mandrel 66 has a first, generallyplanar surface 66 a and a second, spaced-apart generally planar,opposing surface 66 b. Mandrel 66 here includes an upper portion 68 forreceiving the tubular, generally straight-leg section 24 d of thestarting sock and a lower portion for receiving and supporting the lowerportion 24 f of the starting sock.

In the performance of the alternate form of the method of the invention,the turned inside out starting sock shown in FIG. 2 is stretched overthe mandrel 66 in the manner shown in FIGS. 15 and 16. With thisconstruction, the turned inside out starting sock is securely held inposition over the mandrel with both sides of the lower, or sole portion24 f of the foot receiving part of the starting sock being flattened andurged against the sides of the generally planar support portion 68 ofthe mandrel. When the starting sock is properly positioned over themandrel in the manner shown in FIGS. 15 and 16 of the drawings to form afirst assemblage 69, the foot engaging portion of the first or interiorsurface 24 b of the sock is exposed and is maintained in a substantiallyplanar configuration.

Turning to FIG. 17 of the drawings, a generally perspective,diagrammatic view illustrating the emulsion deposition step of thislatest form of the method of the invention is there shown. This stepinvolves the use of a specially designed, apertured stencil 70, whichalso forms a part of the apparatus of the invention. Apertured stencil70, which includes a central portion having a multiplicity ofspaced-apart dot forming apertures 70 a, functions to permit the uniformdeposition of a selected grip-dot forming emulsion on the foot engagingportion of the interior surface 24 b of the sock. As before, thegrip-dot forming emulsion can be selected from a number of well knownprior art curable emulsions, including polymer emulsions, polyvinylchloride emulsions and the like.

In the performance of the emulsion deposition step of this latest formof the invention, the apertured stencil 70 is positioned above the firstassemblage 72 in the manner shown in FIG. 17. Then, using a squeegee orthe like (not shown), the selected emulsion, such as a polymer emulsion,is forced through the apertures 70 a in a manner such that amultiplicity of spaced-apart, uncured grip-dots 74 are controllablydeposited on one side of the foot engaging portion of the interiorsurface 24 b of the sock to form an uncured first precursor (see FIG.18). This done, the uncured grip-dots 74 are then controllably curedinto yieldably deformable, rubber-like cured grip-dots similar to thepreviously described grip-dots 62 a (FIG. 18). This curing step isaccomplished in the manner previously described using a curing means forcuring the emulsion, such as the radiation emitting device 76 shown inFIG. 18 of the drawings, to cure the uncured grip-dots and to form afirst cured precursor 79.

Following this first curing step, assemblage 69 is turned over in themanner depicted in FIG. 19 to expose the second, opposite side of thefirst precursor. This done the apertured stencil 70 is positioned abovethe turned over assemblage 79 in the manner shown in FIG. 19. Then,using a squeegee or the like (not shown), the selected emulsion, such asa polymer emulsion, is forced through the apertures 70 a in a mannersuch that a multiplicity of spaced-apart, uncured grip-dots 74 arecontrollably deposited on the second side of the foot engaging portionof the interior surface 24 b of the sock to form an uncured secondprecursor (see FIG. 20). This done, the uncured grip-dots 74 are thencontrollably cured into yieldably deformable, rubber-like curedgrip-dots similar to the previously described grip-dots 62 a (FIG. 18).This curing step is accomplished in the manner previously describedusing a curing means for curing the emulsion, such as the radiationemitting device 76 shown in FIG. 20 of the drawings, to cure the uncuredgrip-dots and to form a second cured precursor.

Following the second curing step, the second cured precursor thus formedis removed from the mandrel 66. The second precursor formed bydepositing grip-dots on both sides of the interior surface 24 b of thefoot engaging portion of the sock 63 (see FIG. 13) uniquely includes amultiplicity of gripping dots which are strategically located on thelower foot portion of the sock which is normally in engagement with thefoot of the user when the sock is turned inside out from that shown inFIG. 20 and subsequently donned by the user. After the sock is donned bythe user, the strategically located gripping dots once again function toeffectively prevent slippage of the sock relative to the user's foot.

Having now described the invention in detail in accordance with therequirements of the patent statutes, those skilled in this art will haveno difficulty in making changes and modifications in the individualparts or their relative assembly in order to meet specific requirementsor conditions. Such changes and modifications may be made withoutdeparting from the scope and spirit of the invention, as set forth inthe following claims.

1. A gripping sock having inner and outer surfaces, an open top, agenerally tubular-shaped leg section that is dimensioned to receive atleast a portion of the leg of the wearer and a foot section connected tosaid leg section and dimensioned to receive the foot of the wearer, thefoot and leg sections being constructed from a yam and being configuredto stretch when the sock is donned, said foot section having a lowerportion, including an inner surface having a multiplicity of yieldablydeformable grip-dots constructed and arranged to prevent slippage of thesock relative to the wearers foot.
 2. The gripping sock as defined inclaim 1 in which said yieldably deformable grip-dots comprise a polymeremulsion.
 3. The gripping sock as defined in claim 1 in which saidyieldably deformable grip-dots comprise a polyvinyl chloride emulsion.4. The gripping sock as defined in claim 1 in which said yieldablydeformable grip-dots comprise a liquid vinyl.
 5. The gripping sock asdefined in claim 1 in which said yarn comprises natural fibers.
 6. Thegripping sock as defined in claim 1 in which said yarn comprisessynthetic fibers.
 7. The gripping sock as defined in claim 1 in whichsaid yarn comprises synthetic fibers, which incorporate elasticfilaments.
 8. A method of making a gripping sock comprising the stepsof: (a) forming a generally foot-shaped sock having first and secondsurfaces and a lower portion; (b) depositing a multiplicity of dots of agripping material on said first surface of said lower portion of saidsock to form a precursor; and (c) turning said precursor inside out toform a finished sock.
 9. The method as defined in claim 8 in which saidgripping material comprises a polymer emulsion.
 10. The method asdescribed in claim 8 in which said gripping material comprises apolyvinyl chloride emulsion.
 11. The method as described in claim 8 inwhich said gripping material comprises a liquid vinyl.
 12. A method ofmaking a sock using an apparatus comprising a sock positioning mandreland a curing apparatus, said method comprising the steps of: (a) forminga generally foot-shaped sock including a lower portion having first andsecond surfaces; (b) positioning said generally foot-shaped sock on themandrel to form a first assemblage wherein at least a portion of thefirst surface of said lower portion of said generally foot-shaped sockis in engagement with said generally planar portion of said mandrel; (c)depositing a multiplicity of dots of a gripping material on said firstsurface of said lower portion of said generally foot-shaped sock to forman uncured first precursor; (d) using the curing apparatus, curing saidgripping material to form a first cured precursor; and (e) removing saidfirst cured precursor from the mandrel and turning said first curedprecursor inside out to form a finished sock.
 13. The method as definedin claim 12 in which said gripping material comprises a polymeremulsion.
 14. The method as described in claim 13 in which said grippingmaterial comprises a polyvinyl chloride emulsion.
 15. The method asdescribed in claim 13 in which said curing apparatus comprises anirradiation device for producing ultraviolet radiation.
 16. The methodas described in claim 13 in which said curing apparatus comprises aheating device for heating said gripping material.
 17. The method asdefined in claim 13 in which said polymer emulsion comprises a polyvinylchloride emulsion.
 18. The method as defined in claim 13 in which saidmandrel comprises a three-dimensional article.
 19. The method as definedin claim 13 in which said mandrel comprises a generally foot-shaped,planar article.
 20. The method as defined in claim 13 in which saidmandrel comprises a planar article having a sock gripping element. 21.The method as defined in claim 20 in which said sock gripping element isgenerally “V”-shaped.
 22. An apparatus for making a gripping sock from asock having a foot receiving portion for engagement with the foot of theuser, said apparatus comprising: (a) a sock supporting mandrelcomprising a generally planar support member having first and secondends, a generally planar support portion disposed intermediate saidfirst and second ends and a sock capture element located in intermediatesaid first and second ends; (b) a stencil operatively associated withsaid sock supporting mandrel for use in depositing a multiplicity ofdots of a curable emulsion onto said foot receiving portion of saidsock; and (c) curing means for curing said curable emulsion.
 23. Theapparatus as defined in claim 22 in which said supporting mandrel isprovided with an aperture and in which said capture element comprises agenerally “V”-shaped sock capture element extending into said aperture.24. The apparatus as defined in claim 22 in which said supportingmandrel has first and second ends and a generally planar sock supportingplanar portion disposed intermediate said first and second ends.
 25. Theapparatus as defined in claim 22 in which said first end of saidsupporting mandrel is tapered and in which said second end comprises asegment of reduced width.
 24. The apparatus as defined in claim 22 inwhich said curing means comprises a radiation emitting device.